Fabric Shade Assembly with Pockets and Associated Methods of Making and Use

ABSTRACT

A shade assembly adapted to hold a photovoltaic panel thereon includes a shade panel. A first pocket part formed of a substantially clear plastic is connected to the shade panel along a plurality of first pocket edges thereof, a first pocket opening being defined between the shade panel. The first pocket part dimensioned to accommodate insertion of a first end of the photovoltaic panel therein. A second pocket part is also connected to the shade panel along a plurality of second pocket edges thereof, a second pocket opening being defined between the shade panel. The second pocket part is dimensioned to accommodate insertion of a second end of the photovoltaic panel therein. The first and second pocket part openings are substantially opposed. A closure flap extends between the first and second pocket parts and operable to cover the first and second pocket openings.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional Application Ser.No. 61/146,438 filed on Jan. 22, 2009, the contents of which are hereinincorporated by reference in their entirety.

FIELD OF THE INVENTION

The present invention relates to fabric shade assemblies.

BACKGROUND OF THE INVENTION

Shade assemblies, such as umbrellas, have long been employed to protectpeople, animals and equipment from the sun's rays. Thus, by design, alarge amount of solar energy is incident on the fabric of the shadeassemblies. This energy is at least partially reflected or otherwisedissipated to minimize its impact beneath the shade assembly.

SUMMARY OF THE INVENTION

It is an object of the present invention to provide a fabric shadeassembly having pockets for removably holding photovoltaic panelsthereon. A fabric shade assembly according to the present invention,together with suitable photovoltaic panels, advantageously allows atleast a portion of the solar energy incident on the shade assembly to beconverted to electrical power.

According to an embodiment of the present invention, a shade assemblyadapted to hold a photovoltaic panel thereon includes a shade panel. Afirst pocket part formed of a substantially clear plastic is connectedto the shade panel along a plurality of first pocket edges thereof, afirst pocket opening being defined between the shade panel. The firstpocket part dimensioned to accommodate insertion of a first end of thephotovoltaic panel therein. A second pocket part is also connected tothe shade panel along a plurality of second pocket edges thereof, asecond pocket opening being defined between the shade panel. The secondpocket part is dimensioned to accommodate insertion of a second end ofthe photovoltaic panel therein. The first and second pocket partopenings are substantially opposed. A closure flap extends between thefirst and second pocket parts and operable to cover the first and secondpocket openings.

According to a method aspect, the first end of the photovoltaic panel isinserted under the first pocket part through the first pocket opening.The photovoltaic panel is then flexed and the second end of thephotovoltaic panel is inserted under the second pocket part through thesecond pocket opening. The closure flap is closed to cover the first andsecond openings.

These and other objects, aspects and advantages of the present inventionwill be better appreciated in view of the drawings and followingdescription of a preferred embodiment.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a fabric shade assembly having pocketswith photovoltaic panels arranged therein, with hidden components shownin broken lines;

FIG. 2 is a partially exploded top view of the shade assembly of FIG. 1,without photovoltaic panels in the pockets;

FIG. 3 is a detail view of one of the pockets of FIG. 1, with a closureflap in an open position and without a photovoltaic panel; and

FIG. 4 is a detail view of a portion of the pocket of FIG. 3, with theclosure flap in a closed position and with a photovoltaic panel locationshown in broken lines.

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT

Referring to FIGS. 1 and 2, a fabric shade assembly 10 has a pluralityof pockets 12 located thereon. Each pocket 12 is formed from asubstantially transparent material and is adapted to removably hold aphotovoltaic panel 14 therein. Advantageously, the shade assembly 10 isarranged in an umbrella configuration, with a plurality of segments 18arranged around a central support 20. A plurality of lateral supports 22radiate from the central support 20 to spread and support the segments18.

The segments 18 are formed from a plurality of substantially identicalfirst and second shade panels 26, 28. The first panels 26 and secondpanels 28, and the pockets 12 arranged thereon, are substantially mirrorimages of each other.

The structure of each pocket 12 is substantially identical; forefficiency only one pocket 12 will be described in detail. Referring toFIG. 3, the pocket 12 includes a first part 40 and a second part 42. Thefirst and second parts 40, 42 are both formed of a substantiallytransparent material that is attached to the underlying panel 26(28).The first part 40 further includes a closure flap 44 at one end thereof.The closure flap 44 is flexible relative to the rest of the first part40 so as to selectively cover and uncover the second part 42. Afastener, such as a hook and loop fastener, a snap or other fastener,can be arranged between the flap 44 and the second part 42 to releasablysecure the flap 44 to the second part 42.

Advantageously, the first and second parts 40, 42 and the panel 26(28)have interfacing plastic surfaces and are connected by plastic welding.The first part 40 has a first weld 50. Preferably, the first weld 40extends around three edges of the first part 40, leaving a first opening52 under the flap 44. The first weld 40 does not extend to the flap 44,leaving the flap 44 free to bend relative to the rest of the first part40. The first part 40 and the flap 44 can thereby be formed integrallyfrom a single piece of the material.

The second part 42 has a second weld 54. The second weld 54 extendsaround three edges of the second part 42, leaving a second opening 56substantially opposed to, and spaced apart from, the first opening 52.Additionally, a cord gap 60 is formed in the second weld, preferablyopposite a portion of the second opening 56.

Referring to FIG. 4, in use, the pocket 12 removably holds thephotovoltaic panel 14 to the panel 26(28). With the flap 44 raised (seeFIG. 3), a first end of the photovoltaic panel 14 is inserted under thefirst part 40 through the first opening 52, and a second end or base 62of the photovoltaic panel 14 is inserted under the second part 42through the second opening 56. A cord 64 is attached to the base 62 androuted through the gap 60 to carry power generated by the photovoltaicpanel 14.

From the foregoing, it will be appreciated that the pocket 12conveniently allows a photovoltaic panel 14 to be quickly and easilymounted to a shade assembly 10, and subsequently removed and replaced.Thus, repair or replacement of one or more photovoltaic panels 14 can beaccomplished while leaving the shade assembly 10 in place. Similarly,the photovoltaic panels 14 can be readily removed and retained toaccommodate repair or replacement of the shade assembly 10. In additionto holding the photovoltaic panels 14 to the shade assembly 10, thepockets 12 provide protection to the photovoltaic panels 14 fromenvironmental forces like wind and rain, and aid in the routing of thecord 64.

Though not necessarily limited to such, the shade assembly 10 andpockets 12 are advantageously used in connection with lightweight,flexible, nano-enabled photovoltaic materials, such as Power Plastic®photovoltaic panels produced by Konarka Technologies, Inc.

Referring to FIG. 3, exemplary dimensions for the depicted pocket 12embodiment include an overall length (from left to right, in FIG. 3) of1320 mm and width (from top to bottom, in FIG. 3) of 354 mm. First andsecond welds 50, 54 extend inwards 10 mm from the sides of therespective first and second parts 40, 42. The length of the first part50 is 1320 mm, with a length of 1220 mm to the first opening 52 and aflap length of 100 mm. The length of the second part is preferably 50mm, with 50 mm between the first and second openings 52, 56. The gap 60is 20 mm wide. Preferably, the first and second parts 40, 42 areconnected to the panel 26(28) such that, when the shade assembly 10 isin place, the first part 40 is an upper part, and the second part 42 isa lower part (see FIG. 2). However, the present invention is notnecessarily limited to such dimensions, nor to a shade assembly havingan umbrella configuration, or to the quantities, shapes and sizes ofsegments or panels shown herein.

As discussed above, the first and second parts 40, 42 and the panels26(28) preferably have interfacing plastic surfaces and are connected byplastic welding. Although not necessarily limited to such materials, itis preferred that the panels 26(28) be formed from apolyvinylchloride—(PVC) coated polyester fabric or apolytetrafluoroethylene—(PTFE) coated fiberglass fabric, which has beentreated for flame retardancy. The first and second parts 40, 42 arepreferably formed from a clear ethylene tetrafluoroethylene (ETFE) film.

Preferably, a computer controlled plotter/cutter machine with an airvacuum table bed is used for plotting and cutting of the EFTE film tospecified dimensions. Advantageously, the cut EFTE film components areinitially stitched to the underlying fabric panels. For this purpose, anindustrial grade sewing machine can be employed, preferably with atleast a single needle and a high-speed, oil bath-type chain stitch withwalking foot operation. Industrial sewing machines sold under the brandsSinger™, Juki™ and Pfaff™ have been found suitable. Tenara™-brandthread, produced by the W.L. Gore Company, has been found suitable forits resistance to ultraviolet (UV) light degradation.

Where PVC-coated polyester fabrics are to be used, a high frequency (HF)electronic welding machine is preferred for welding the EFTE filmcomponents to the fabric. An HF welding machine having at least a 10kilowatt welding capacity, with a oil cooled/water cooled weldingelectrode holder, and an individual air pressure regulator valve forgraduated control of downward welding bar pressure, has been foundsuitable. Exemplary machine settings include 50-75 pounds per squareinch (psi) downward welding bar pressure, a power setting of 30-60milliamps, a weld time of 6-10 seconds, and a cooling time of 3-6seconds between welds.

Where PTFE-coated fiberglass fabrics are to be used, a direct heat PTFEwelding machine is preferred for welding the EFTE film components to thefabric. A direct heat welding machine with a minimum electrode thrustcapacity of 4 kilonewtons (Kn) and 1.5 meter length has been foundsuitable. A catalyst including a copolymer of hexafluoropropylene andtetrafluoroethylene is advantageously employed in the welding process. Aweld time of approximately three minutes has been found to ensure asufficient weld.

The above described embodiment and method of making are provided forillustrative and exemplary purposes; the present invention is notnecessarily limited thereto. Rather, those skilled in the art willappreciate that various modifications, as well as adaptations forparticular circumstances, are possible within the scope of the inventionas herein shown and described and of the appended claims.

1. A shade assembly adapted to hold a photovoltaic panel thereon, theshade assembly comprising: a shade panel; a first pocket part formed ofa substantially clear plastic connected to the shade panel along aplurality of first pocket edges thereof, a first pocket opening beingdefined between the shade panel and the first pocket part dimensioned toaccommodate insertion of a first end of the photovoltaic panel therein;a second pocket part connected to the shade panel along a plurality ofsecond pocket edges thereof, a second pocket opening being definedbetween the shade panel and the second pocket part dimensioned toaccommodate insertion of a second end of the photovoltaic panel therein,the first and second pocket part openings being substantially opposed;and a closure flap extending between the first and second pocket partsand operable to cover the first and second pocket openings.
 2. Theassembly of claim 1, wherein the closure flap is integral with the firstpocket part.
 3. The assembly of claim 2, wherein the shade assembly isoriented such that the first pocket part is an upper part.
 4. Theassembly of claim 3, wherein the closure flap substantially overlies thesecond pocket part when closed.
 5. The assembly of claim 3, wherein thea cord gap is defined between the second part and the shade panel alonga lower edge of the second part, the cord gap being dimensioned to routea cord for connection to the second end of the photovoltaic paneltherethrough.
 6. The assembly of claim 1, wherein the first and secondpocket part openings are spaced apart.
 7. The assembly of claim 1,wherein the first pocket part is substantially longer than the secondpocket part.
 8. A method of using the shade assembly of claim 1, themethod comprising: inserting the first end of the photovoltaic panelunder the first pocket part through the first pocket opening; flexingthe photovoltaic panel; inserting the second end of the photovoltaicpanel under the second pocket part through the second pocket opening;closing the closure flap to cover the first and second openings.
 9. Themethod of claim 8, wherein the closure flap is integral with the firstpocket part, the shade assembly is oriented such that the first pocketpart is an upper part, the closure flap substantially overlies thesecond pocket part when closed, and a cord gap is defined between thesecond part and the shade panel along a lower edge of the second part,the method further comprising: routing a cord through the cord gap beingand connecting the cord to the second end of the photovoltaic panel. 10.A shade assembly adapted to hold a photovoltaic panel thereon, the shadeassembly comprising: at least one shade panel; and a pocket attached tothe shade panel and including: a first part having a closure flap at afirst end thereof; and a second part underlying the flexible closureflap; wherein the pocket is dimensioned to accommodate the photovoltaicpanel therein and at least one of the first and second part are formedfrom a substantially transparent polymer material.
 11. The assembly ofclaim 10, wherein the at least one shade panel is a fabric panel. 12.The assembly of claim 11, wherein the at least one shade panel is formedof least one of a polyvinylchloride-coated fabric and apolytetrafluoroethylene-coated fiberglass fabric.
 13. The assembly ofclaim 10, wherein at least one of the first and second parts is formedof a plastic material.
 14. The assembly of claim 13, wherein at leastone of the first and second parts is thermally welded to the shadepanel.
 15. The assembly of claim 13, wherein at least one of the firstand second parts is formed of an ethylene tetrafluoroethylene film. 16.The assembly of claim 10, wherein the first part has four edges, firstpart connections to the shade panel being formed only along three edgesthereof such that a first opening is defined between the first part andthe shade panel under the closure flap.
 17. The assembly of claim 16,wherein the closure flap is flexible the connections between the shadepanel and the first part do not extend under any edges of the closureflap.
 18. The assembly of claim 16, wherein the second part has fouredges, second part connections to the shade panel being formed onlyalong three edges thereof such that a second opening, substantiallyopposed to the first opening, is defined between the second part and theshade panel under the closure flap.
 19. The assembly of claim 10,wherein the second part has four edges, second part connections to theshade panel being formed only along three edges thereof such that asecond opening is defined between the second part and the shade panelunder the closure flap.
 20. The assembly of claim 19, wherein a gap isformed in the second part connection to the shade panel opposite thesecond opening, adapted to accommodate a cord of the photovoltaic paneltherethrough.